Casting mold



Jan. 27, 1 942. MARKS A 2,270,885

CASTING MOLD 7 Filed Dec. 18, 1935 3 Sheets-Sheei. l

NMMNNE IF II 155,, D, a u INVENTORS 1 a 9 22;

s )2 Marks" radar 'ATTORN Jan. 27, 1942. A. A. MARKs EIAL CASTING 'moLn Filed 09. 18-, 19:59

3 Sheets-Sheet 2 INVENTQRS Jan. 27, 1942. AA, MARKS ETAL 7 2,270,885

CASTING MOLD Filed Dec. 18, 1939 s Sheets-Sheet 3 29 8 4 INVENTOR.

. ,5 '91:; mm mnd Patented Jan. 27, 1942 t UNITED STATE s PATENT OFFICE CASTING MOLD Alexander Ashton Marks,'Uniontown, and John D. Augustine, South Uniontown, Pa.;' said Augustine assignor to Richmond Radiator Compan;y','lnc., Uniontown, Pa... a corporation of Delaware Application December 18, 1939, Serial No. 309,810

' 8 Claims. Our invention is an improved casting mold.

Our improvements are designed primarilyto permit the casting integrally of. relatively large Our improvementsare further designed to improve the distribution and solidification oi the metal or other casting liquid in the mold and the the cope and drag mold-parts and another pattern is used for making the cheek mold-parts. 7

Each mold section has a fiat face'and an intaglio face and all the intagli o faces contain similar impressions. Each impression preferably forms a horizontal concave casting space, vertical casting spaces normal to the plane of the I horizontal casting space, prints adjacent to the vertical casting spaces for receiving core end members, channels connecting the castingspaces with individual horizontal gates, and vertical holes at the ends of the gates and which serve both as molten metal inlets and as gasvents.

venting of gases from the mold in making such castings so that no part of the mold is subjected to excessive pressure from the casting metal, the formation of blow holes is minimized, and the waste pieces formed in the sprue holes, gates and runners are readily separated from the casting.

Our improvements. are further designed to i provide a multi-part mold containing a series of superposed casting spaces each containing a core having end members firmly securing the core body against movement in any direction, and containing runners connecting the casting spaces with'their respective gates.

'I'he'vertical casting spaces, prints and vertical holes in superposed mold sections register and communicate with one another respectively.

The cope and drag mold sections differ'irom the cheek mold sections in thickness and in depth of the vertical casting spaces and provide a closed top and bottom for the top and bottom vertical casting spaces and a closed bottom for the vertical holes. The top of each vertical hole in the cope mold section may be surrounded by a runner box of core sand.

Between the intaglio faces of each pair'of mold sections there is housed a baked "core so molded s, of sand mixedwith a binder that its horizontal Our improvements are particularly adapted for use in, the manufacture of integral castings having a plurality of rows of hollow tubes with their ends integrally connected by header ele-- ments such, for instance, as the tubular heat exchangers with integral headers shown "in the ap- "plication of A. A. Marks, Serial No; 267,745, filed April 14, 1939. A further example of the type of work for which our invention is particularly designed is the casting, as an integral unit, of all the radiator sections required to' make a complete radiator having an enclosing shell of the general character shown in Letters Patent No. 2,083,028 of June 8, 1937.

' and the latter preferably contain internal pas- Our invention permits the use of a single pat.-

tions of the casting difler from the intermediate sections thereof, one pattern is used for making body partly fills the horizontal casting space and its ends fit into theprints of such' mold sections.

The mold sections and cores are relatively porous sages facilitating the venting of gases, which may escape through the mold, through the ver-- tical holes and from between the mold sections. The formation of 'blow holes in the casting due to internal pressure from gases is thereby eliminated or minimized A suitable number of the baked mold sections and coresare superimposed upon one another so that their vertical holes at the ends of the gates register and their vertical casting spaces register. The gates, runner,channels, and outlines of the impressions in intaglio faces of ad'- jacent mold sections coincidewith one another,

and a core is housed in each casting space so formed. Sometimes openings are formed from a horizontal casting space through the flat face of a mold section, and in such case imperiorate sections of the flat face of an adjacent mold section cover such openings;

e The end members of the core disposed between;

and spaced from the intaglio faces of each pair of sections partially fills the prints or slots of the pair.

of mold sections between'which the body of such core lies. The walls of these end members so abut the walls of the slots as to prevent movement of the core in its casting space in any di-= rection. End members of superimposed cores preferably abut one another and contain grooves forming core runners connecting the mold runners with the vertical casting spaces. The inner faces of core end sections are spaced from the inner faces of the vertical casting spaces and form a face for molding and giving form to the outer surface of casting members connecting tubes formed around the core bodies.

The impression in the intaglio face of each mold section may be symmetrical or asymmetrical with respect to the longitudinal center line thereof, but the vertical holes at the ends of the gates and-the through slots formed by the vertical casting spaces and adjacent prints are symmetrical with respect to such center line and are also symmetrically arranged with respect to the transverse center line of the mold sections.

When the impressions are asymmetrical, the mold, sections are preferably assembled so that the bulk of the casting space formed by the impressions of one pair of sections lies on one side of the longitudinal center line and the bulk of the casting space formed by the impressions of the next pair of sections lies on the opposite side of the longitudinal center line.- Such transposition is effected by turning the mold sections of the second pair end for end with respect to the mold sections of the first pair.

The vertical casting spaces and prints in the drag and cope mold sections of the series do not extend completely through such sections and the Wall areas at the ends thereof respectively mold different types of castings may be made from the same pattern by changing the positions of consecutive pairs of mold sections made therefrom relatively to one another, as, for instance, by placing the head of the impression in one pair of sections adjacent to the foot of the impression in an adjacent pair of mold sections.

iii

aarosee different angle; Fig. 9 is a perspective view of a further flask cheek section with an intermediate mold section therein, and is similar to Fig. 6 but viewed from a slightly different angle; Fig. is a perspective view of an inverted core similar to the core shown in Fig. 4 and adapted for use in conjunction with a cope mold section or drag mold section; Fig. 11 is a perspective View of the flask drag section withnmbottomgold section tional view through a flask, mold and casting,

The characteristic features and advantages of 7 our improvements will further appear from the following description and the accompanying drawings in illustration thereof.

In the drawings, Fig. l is a perspective view of a flask containing mold sections built up in accordance with our invention; Fig. 2 is a broken transverse sectional view of the flask and :mold taken on the line 22 of Fig. 1 and showing a casting therein; Fig. 3 is a perspective view of the cope of the flask of Figs. 1 and 2 and of the cope mold section therein; Fig. 4 is a perspective view showing a core suitable for use in conjunction with the cope mold section or drag mold section; Fig. 5 is a perspective view of a flask cheek section with an intermediate mold section therein; Fig. 6 is a perspective view of an inverted flask cheek section with an intermediate mold section therein; Fig. 7 is a perspective view of a core suitable for use between the intaglio faces of intermediate moldsections; Fig. 81 is a perspective view of a second flask cheek section with an intermediate mold section therein, and is similar to Fig.5 but viewed from a slightly including wastage metal, taken on the line iii-92 of Fig. 13; and Fig. 13 is an irregular longitudinal vertical sectional View through a flask, mold and casting, including wastage metal, taken on the line [13-43 of Fig. 12; hatching, stippling and mold and core division lines being omitted from Figs. 12 and 13 for the sake of clearness.

, The flask sections and the mold sections shown in Figs. 3 and 11 are identical with one another excepting that the vertical holes at the ends of the gates extend entirely through the mold section of Fig. 3 and are surrounded by casting boxes. The cores shown in Figs. 4 and 10 are identical and the core shown in Fig. 7 differs therefrom only in the extent of the channels in the end members forming core runners. The flask cheek sections and intermediate mold sections shown in Figs. 5, 6, 8 and 9 are identical with one another and differ from the flask and mold sections shown in Figs. 3 and 11 only in thickness and the results of the differences in thickness.

In the embodiment of our invention illustrated in the drawings, a flask, composed of the drag i, cheeks 2, and cope 3, contains a multi-part mold composed of the bottom mold section it, intermediate mold sections 5, top section 6, and cores l and i. While the flask members are necessary for the molding and baking of the mold parts, the respective flask members may be composed of hinged or detachable members to permit the removal of the flask from the mold before casting.

In making the mold sections 4i, 5 and ii, the flask members i, 2 aud t may be placed upon flat plates and each flask member is covered by a pattern. The same pattern may be used conseeutively with all the flask sections 2 and in some instances the same pattern may be also used with the flask sections i and 3. Where, however, the ends of the casting are to be provided with flanges or other members differing in width or character from the members between the intermediate casting sections, it is preferable to use a separate pattern with the flask sections i and t. In the,present instance, the pattern used with the flask members i and 3 forms vertical casting spaces in .the mold sections iand S deeper than the corresponding vertical casting spaces in the sections 5 and such pattern isprovided with detachable extensions for completely penetrating the cope section to form vertical holes at the ends of the cope gates.

Core sand is compacted in the flask members around the patterns in any suitable manner, and when the pattern is removed from each flask member there is left in-the sand therein a complete imprint of the pattern. ,The thickness of the mold section 3 is sufficient to provide a continuous bottom for the mold and the thickness of the copesection 6 is sufilcient to form a mold cover which iscontinuous excepting for the sprue holes and riser holes therein.

As shown in the drawings, each of the mold sections 6, 5 and a formed as above described .Each intermediate mold section contains throughslots forming vertical castingspaces I4 I and prints I5 adjacent thereto. The mold sections 4 and 5 each contain slots passing only partly therethrough and similar in general outline and in relative positions to, but of greater depth than, the slots in the mold sections 5. The slots in the, sections 4 and 9 provide vertical adapted to register'with prints I5.

Each intermediate mold section 5 contains vertical through holes I6 at the ends of the gate grooves I2 thereof. The top mold section has vertical holes |6a passing therethrough, and aligned with the holes I6, and the-mold section 4 has vertical holes Ifib passing only partly therethrough and aligned with the holes I6. The upper ends of theholes Ilia are surrounded byI runner boxes I1.

In the example shown', each impression 8 for molding an outer surface of a tubular portion of a casting, consists of parallel troughs I8 and I8. Depressions I9 and 19 extend along the upper edges of the troughs I8 and I8.

The walls of each trough contain staggered transverse grooves 20 and 20 the apexes of which may form openings in the flat faces of the intermediate mold sections 5 but do not penetrate through the thicker mold sections 4 and 6. The

' openings formed by the slots 20 and 2|! in one intermediate mold section are covered by an imperforate portion of the'flat face of an adjacent mold section.

The troughs I8 and I8 have similar, tapering ends I8a merging into the inner faces of the of the sections 4 and 6. I

The cores 1 and, comprise end member's 2| connected by spaced similar cross-bars, 22, each of substantially rhomboidal cross-section. The cross-bars and end members may contain internal passages In to facilitate escape of gases generated within the coresfrom the binder mixed with the core sand. The respective cross-bars 1 have tapering ends 22a, and the contours of the cross-bars 22 and their ends 22a are complementary to the contours of,the troughs I8 and I8 and their tapering ends I811 Each crossbar 22 has a similar top and bottom face, and-v contains sinuous grooves 26- and 21 along the longitudinal ridges thereof.

full height of the end members 2| and communicating with the runner grooves 28a and 28m. In both the cores 1 and.|'- the inner faces of the end members 2| are devoid 0! runner grooves.

similar faces of an adjacent section; shallow grooves II to form mold runners, and deeper grooves I2 to form gates.

When a mold for casting is to be made', a core I is placed in the bottom mold'section 4 with the outer faces of the core end members 2I engaging'the outer faces of the prints |5a and the side faces of the end members 2| engaging the side faces of the slots a, and with the core runners 29 and- 28 registering with the mold casting spaces I4a communicating with the vertical casting spaces I4 and also provide prints Ila vertical casting spaces I4 of the sections'5 or |4a The core I, complementary to the section 4.

' member 2| and communicating with the grooves J28. The core I used in conjunction with the section 6 is inverted so that its runners 28 are in the bottom faces of its end members 2| and its runner grooves 29 extend only part way up theend facesof the members 2|. The cores 1' which are usjed in conjunction with two mold sections 5 have runner channels 28a and 28a in the upper-and lower surfaces of the member An intermediate mold member 5 is laid on topof the member 4 so that the parting faces of the two members contact and the" imprint in the member'5 registers with the imprint in the member 4 so as to form gates by the registration of the gate grooves, I2, to form runners. by the registration of the runner grooves II, to form a casting space for transverse elements by registration of the vertical casting spaces 14a and I4, and toform a horizontal casting space around the core 1.'

A further intermediate mold section 5 islaid with its fiat face on the flat face of the first mold section 5, a core 1" is laid in the second mold section 5, and a further mold section 5 is laid with its intaglio face in juxtaposition to the intaglio face of the second laid mold section 5, the bars of the second core section 1' being housed within the casting spaces thus formed.

The second pair of mold sections may be laid with their casting Spaces vertically aligned with the casting spaces of the first pair' of mold sections, but preferably the second pair of mold sections are turned end for end with respect to the first pair of mold sections so that the casting spaces of the second pair of moldsections are ofiset relatively to the casting spaces of the first pairof mold sections, as shown inFig. 2.

Further pairs of mold sections 5 and cores I may be laid to any desired height to form a casting containing any desired number of tubes.

The top of the stack of mold sections is formed by placing an inverted core 1 above the last intermediate section "5 and covering it. with the cope 6 with its intaglio face in registration with the intaglio face of such mold section 5'.

The several mold sections may be accurately aligned by aligning the apertures 38 in the lugs on the flask parts so that the vertical holes at the ends of the gates are all vertically aligned with the pouring tubes on the top of the cope.

Preferably metal is simultaneously poured in diagonally positioned sprue holes. rises in the sprue holes, it first flows into the gates formed by the grooves in'the bottom pair of mold parts 4'an'd 5, thence flows through the mold runners and core runners into the vertical casting spaces Ma and I4 and thence into the casting space surrounding the bottom core I.

by the grooves I2 in the next pair of mold sections 5, thence through, the corresponding runners into the-vertical casting spaces of the second pair of mold sections, and thence into the casting space surrounding the second core I. The metal in the vertical casting spaces formed by the superposed mold sections forms elenients con- 2I andhave runner grooves 29a extending the tinu'ous with one another and integrally united As the metal with the metal in the casting spaces surrounding longitudinal fins on the front and rear edges of the tube bodies; that the tapering ends Eta mold the outer surfaces of the flaring ends of the tubes; that'the metal solidifying in the vertical casting spaces has its outer surface molded by the inner surfaces of the members 2i and its inner surface molded by the inner surfaces of the slots id and Mia to form continuous integral headers connecting the tube ends with one another;,that the bars 22 mold the inner surfaces of the tubes; and that the grooves 2e and 2'! mold sinuous baffles integrally on the inner surfaces of the tubes.

The gases evolved from the disintegration of the binder contained in the core '5 escapes through the ends of the tubes, and through the runners, gates and riser holes that are not being used for pouring, as well as through the'porous structure of the mold and between the members thereof.'-

Having described our invention, we claim:

1. A mold for casting, comprising top, bottom and intermediate mold sections having partings between them and arranged in complementary pairs, each of said mold sections containing a shallow concavity with parting faces beside it and'each of said intermediate mold sections having a substantially fiat parting face on the opposite side thereof from its hollow concavity, and

cavities communicate with the partings between fiat parting surfaces aforesaid.

of mold sections arranged in pairs, each pairthrough passages through which said hollow concore seated in said concavities and having enlarged ends seated in said slots, said ends containing spaced channels in the tops, bottoms and outer faces thereof. 4

d. A mold for castingcomprising mold sections along said concavity transversely thereto and open through the flat face of said section.

6. A mold for casting comprising a plurality of mold sections each containing an imprint forming a pair of parallel shallow concavities, a

through slot extending across substantially the entire width of both said concavities, a gate groove parallelto and of lesser depth than said slot and spaced therefrom by a ridge, runners in the top of said ridge, and a through hole at an end of said gate groove; and a core comprising spaced bars connected by an end member in said-concavities and slot; said end member containing runners complementary to the runners in said ridge.

-7. A mold comprising mold sections arranged in complementary pairs, each pair having juxtaposed faces each containing an imprint forming a longitudinal shallow concavity and a through slot extending transversely to the concavity; and a core for each pair of complementary sections,

. each core having an end member seated in the through slots of its pair to maintain the registration thereof and superposed cores forming having juxtaposed faces containing imprintsforming complementary shallow concavities and slots extending transversely to the faces of said sections and of greater depths than said con-.

cavities, and a core having a body extending the length of said complementary concavities and having enlarged ends bearing against the outer walls and spaced-from the inner walls of said slots to prevent longitudinal shifting of said core bet ween them runners communicating with the concavities below and above such runners.

'8.-A mold for casting comprising a plurality of mold sections forming complementary pairs; 

